08/27/2026
On the morning of April 6, 1938, twenty-seven-year-old American chemist Roy J. Plunkett was working at the DuPont Jackson Laboratory in Deepwater, New Jersey. Plunkett was assigned to a team tasked with creating a non-toxic, non-flammable alternative to existing commercial refrigerants like sulfur dioxide and ammonia, which regularly posed deadly poisoning risks if household refrigerators developed leaks.
To synthesize a new chlorofluorocarbon refrigerant, Plunkett and his laboratory assistant, Jack Rebok, produced roughly one hundred pounds of tetrafluoroethylene gas (TFE). They stored the compressed gas in small steel cylinders, keeping them frozen on dry ice to prevent spontaneous chemical reactions until they were ready to be used.
On that historic morning, Plunkett mounted one of the chilled cylinders onto a scale and turned the brass release valve to vent the pressurized gas into a reaction chamber with hydrochloric acid.
Nothing came out.
Plunkett checked the scale reading. The cylinder still registered the exact heavy weight of a full tank of gas. He tapped the brass valve with a wrench and ran a wire through the nozzle to clear any possible ice blockage, but the gas refused to flow. By all ordinary measures, a gas stored in a pressurized container cannot simply disappear while leaving its weight behind.
Refusing to discard the container, Plunkett and Rebok unscrewed the valve entirely and tipped the cylinder upside down. A small amount of a strange, slippery white powder fell out onto the workbench.
Intrigued, Plunkett grabbed a handsaw and cut the heavy steel cylinder completely in half.
Inside, they found that the pressurized TFE gas had completely vanished. In its place, the interior walls of the tank were coated with a smooth, waxy white substance. Under the intense cold and pressure inside the tank, with the iron walls acting as an accidental catalyst, the gas molecules had linked together into long polymer chains—a process known as polymerization.
Plunkett had accidentally created polytetrafluoroethylene, or PTFE.
When Plunkett began testing the mysterious white powder, its physical properties proved astonishing. The substance was chemically inert; neither boiling acids, corrosive bases, nor powerful solvents could dissolve it. It had an extremely high melting point, was an exceptional electrical insulator, and possessed the lowest coefficient of friction of any known solid material. Virtually nothing could stick to its surface.
DuPont patented the polymer in 1941 and registered the trademark name Teflon in 1945.
During World War II, Teflon was immediately classified as a military secret. Because of its extreme corrosion resistance, it was used to coat valves, gaskets, and pipes carrying highly corrosive uranium hexafluoride gas in the Manhattan Project.
In 1954, French engineer Marc Grégoire used PTFE to coat his fishing tackle, and at his wife Colette’s suggestion, applied it to an aluminum cooking pan, giving birth to the world-famous Tefal non-stick cookware brand.
Roy Plunkett’s accidental discovery not only revolutionized commercial cookware, but also became indispensable in aerospace engineering, medical implants, waterproof clothing, and industrial manufacturing worldwide.